U.S. patent number 11,215,097 [Application Number 16/933,671] was granted by the patent office on 2022-01-04 for automated diesel exhaust fluid (def) system and method.
This patent grant is currently assigned to Chemoil Energy Services LLC. The grantee listed for this patent is Chemoil Corporation. Invention is credited to Brennan Schmidt.
United States Patent |
11,215,097 |
Schmidt |
January 4, 2022 |
Automated diesel exhaust fluid (DEF) system and method
Abstract
An automated diesel exhaust fluid (DEF) system and method for
refilling DEF. The automated DEF system provides DEF refilling
after an initial setup and without manual intervention. The
automated DEF system includes a electric DEF flow control device
that controls the flow of DEF. The electric DEF flow control device
may include control circuitry, an electrics enclosure that encloses
the control circuity, an electric fluid sensor, a valve, a beacon
light, a status light, a button, a threaded swivel connection, and
a mandrel on the inside of the threaded swivel connection.
Inventors: |
Schmidt; Brennan (Weatherford,
OK) |
Applicant: |
Name |
City |
State |
Country |
Type |
Chemoil Corporation |
Oklahoma City |
OK |
US |
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Assignee: |
Chemoil Energy Services LLC
(Oklahoma City, OK)
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Family
ID: |
1000006033470 |
Appl.
No.: |
16/933,671 |
Filed: |
July 20, 2020 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20210017890 A1 |
Jan 21, 2021 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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62876307 |
Jul 19, 2019 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F01N
3/2896 (20130101); F01N 3/2066 (20130101); F01N
2390/02 (20130101); F01N 2550/05 (20130101); F01N
2610/1433 (20130101); F01N 2610/142 (20130101); F01N
2610/02 (20130101); F01N 2610/1413 (20130101); F01N
2610/148 (20130101); F01N 2900/1814 (20130101) |
Current International
Class: |
F01N
3/20 (20060101); F01N 3/28 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
International Search Report & Written Opinion for International
Application No. PCT/US2020/042648, report dated Dec. 8, 2020; pp.
1-17. cited by applicant.
|
Primary Examiner: Tran; Binh Q
Attorney, Agent or Firm: Bracewell LLP
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional Application
No. 62/876,307 filed Jul. 19, 2019, and titled "AUTOMATED DIESEL
EXHAUST FLUID (DEF) SYSTEM AND METHOD." For purposes of United
States patent practice, this application incorporates the contents
of the Provisional Application by reference in its entirety.
Claims
What is claimed is:
1. A diesel exhaust fluid (DEF) refilling system, comprising: a
supply tank comprising DEF; a supply line connecting the supply
tank to a DEF tank configured to supply DEF to a diesel engine; a
DEF flow control device in fluid communication with the supply
line, the DEF flow control device comprising: an enclosure
containing control circuitry; a valve having an inlet and an outlet
and moveable between an open position and a closed position, the
open position configured to permit DEF flow through the valve and
the closed position configured to block DEF flow through the valve,
the valve outlet in fluid communication with the DEF tank; a valve
actuator operable to move the valve between the open position and
the closed position; an electric fluid sensor disposed in a sensor
housing and comprising a shaft extending into the DEF tank, the
shaft comprising a slot such that the electric fluid sensor senses
DEF when the slot is submerged; and a battery configured to power
the control circuitry, the valve actuator, and the electric fluid
sensor, wherein the control circuitry comprises logic configured to
move the valve between the open position and the closed position in
response to a signal provided by the electric fluid sensor.
2. The system of claim 1, comprising a feeder line, the feeder line
further connecting the supply line to the DEF tank.
3. The system of claim 1, wherein the supply tank is positioned on
a deck of a frame raised to a higher elevation than an inlet of the
DEF tank.
4. The system of claim 1, wherein the supply tank is positioned on
a trailer having a pump operable to supply DEF from the supply tank
at a minimum pressure.
5. The system of claim 1, wherein the diesel engine provides power
to a fluid pump.
6. The system of claim 1, wherein the DEF flow control device
comprises a first light and second light, the first light
configured to indicate an alarm and the second light configured to
indicate operation of the electric fluid sensor.
7. The system of claim 1, wherein the DEF flow control device
comprises a button configured to initiate operation of the electric
fluid sensor.
8. The system of claim 1, wherein the valve comprises a motorized
ball valve.
9. The system of claim 1, wherein the valve comprises a solenoid
valve.
10. The system of claim 1, wherein the DEF flow control device
comprises a threaded swivel connection configured to couple the DEF
flow control device to the DEF tank.
11. The system of claim 1, wherein the DEF flow control device
comprises a mandrel coupled to the electric fluid sensor, wherein
the mandrel comprises a DEF fill port in fluid communication with
the DEF tank and the valve outlet is in fluid communication with
the DEF fill port.
12. A diesel exhaust fluid (DEF) flow control device, comprising:
an enclosure containing control circuitry; a valve having an inlet
and an outlet and moveable between an open position and a closed
position, the open position configured to permit DEF flow through
the valve and the closed position configured to block DEF flow
through the valve; a valve actuator operable to move the valve
between the open position and the closed position; an electric
fluid sensor disposed in a sensor housing and comprising a shaft,
the shaft comprising a slot such that the electric fluid sensor
senses DEF when the slot is submerged; and a mandrel coupled to the
electric fluid sensor and comprising a DEF fill port for providing
fluid to a DEF tank, wherein the valve outlet is in fluid
communication with the DEF fill port; and a battery configured to
power the control circuitry, the valve actuator, and the electric
fluid sensor, wherein the control circuitry comprises logic
configured to move the valve between the open position and the
closed position in response to a signal provided by the electric
fluid sensor.
13. The DEF flow control device of claim 12, wherein the DEF flow
control device comprises a threaded swivel connection configured to
couple the DEF flow control device to the DEF tank.
14. The DEF flow control device of claim 12, comprising a pressure
gauge configured to measure pressure at the inlet.
15. The DEF flow control device of claim 12, wherein the valve
comprises a motorized ball valve.
16. A method of controlling diesel exhaust fluid (DEF) flow to a
DEF tank for a diesel engine, comprising using a DEF flow control
device coupled to the DEF tank, the DEF flow control device
configured to stop the flow of DEF from a supply tank when the DEF
flow control device detects fluid via an electric fluid sensor
extending into the DEF tank, the DEF flow control device
comprising: an enclosure containing control circuitry; a valve
having an inlet and an outlet and moveable between an open position
and a closed position, the open position configured to permit DEF
flow through the valve and the closed position configured to block
DEF flow through the valve, the outlet in fluid communication with
the DEF tank; a valve actuator operable to move the valve between
the open position and the closed position; the electric fluid
sensor disposed in a sensor housing and comprising a shaft
extending from the body into the DEF tank, the shaft comprising a
slot such that the electric fluid sensor senses DEF when the slot
is submerged; and a battery configured to power the control
circuitry, the valve actuator, and the electric fluid sensor.
17. The method of claim 16, wherein the DEF flow control device is
in fluid communication with supply line of a gravity fed
system.
18. The method of claim 16, wherein the diesel engine provides
power to a fluid pump.
19. The method of claim 16, wherein the valve comprises a motorized
ball valve.
20. A diesel exhaust fluid (DEF) flow control device, comprising:
an enclosure containing control circuitry; a valve having an inlet
and an outlet and moveable between an open position and a closed
position, the open position configured to permit DEF flow through
the valve and the closed position configured to block DEF flow
through the valve outlet, the valve outlet in fluid communication
with a DEF fill port; a valve actuator operable to move the valve
between the open position and the closed position; means for
sensing DEF in a DEF tank and generating a signal in response
thereto; and a mandrel comprising a DEF fill port for providing
fluid to the DEF tank, wherein the valve outlet is in fluid
communication with the DEF fill port, wherein the control circuitry
comprises logic configured to move the valve between the open
position and the closed position in response to the signal.
Description
BACKGROUND
Field of the Disclosure
The present disclosure generally relates to the operation of diesel
engines. More specifically, embodiments of the disclosure relate to
controlling emissions from such engines using diesel exhaust fluid
(DEF).
Description of the Related Art
As environmental standards have become more strict, diesel exhaust
fluid (DEF) has been used to reduce emissions from diesel engines.
Some diesel engines, such as those used in oil and gas operations
such as fracking, may burn significant amounts of DEF. In such
environments, DEF is manually refilled at the equipment using a
trailer with a tank, a pump, and hose reel. However, this manual
refilling may be labor intensive, time consuming, and expensive. In
addition, the manual refilling may increase dirt and contamination
due to the frequent removal of caps and exposure of the tanks to
dirt and dust in the air. Additionally, the hoses may be dragged in
the dirt and may also introduce contaminants into the DEF tanks
from the end of the nozzle. The manual refilling also may also
introduce human error regarding the frequency of refilling and the
consistency in following proper procedure.
SUMMARY
In one embodiment, a diesel exhaust fluid (DEF) refilling system is
provided. The system includes a supply tank having DEF, a supply
line connecting the supply tank to a DEF tank configured to supply
DEF to a diesel engine, and a DEF flow control device in fluid
communication with the main supply line. The DEF flow control
device includes an enclosure containing control circuity and a
valve having an inlet and an outlet and moveable between an open
position and a closed position, the open position configured to
enable DEF flow through the valve and the closed position
configured to block DEF flow through the valve, the valve outlet in
fluid communication with the DEF tank. The DEF flow control device
also includes a valve actuator operable to move the valve between
the open position and the closed position and an electric fluid
sensor disposed in a sensor housing and having a shaft extending
into the DEF tank, the shaft having a slot such that the electric
fluid sensor senses DEF when the slot is submerged. The DEF flow
control device also includes a battery configured to power the
control circuity, the valve actuator, and the electric fluid
sensor. The control circuity includes logic configured to move the
valve between the open position and the closed position in response
to a signal provided by the electric fluid sensor.
In some embodiments, the system includes a feeder line, the feeder
line further connecting the main supply line to the DEF tank. In
some embodiments, the supply tank is positioned on a deck of a
frame raised to a higher elevation than an inlet of the DEF tank.
In some embodiments, the supply tank is positioned on a trailer
having a pump operable to supply DEF from the supply tank at a
minimum pressure. In some embodiments, the diesel engine provides
power to a fluid pump. In some embodiments, the DEF flow control
device includes a first light and second light, the first light
configured to indicate an alarm and the second light configured to
indicate operation of the electric fluid sensor. In some
embodiments, the DEF flow control device includes a button
configured to initiate operation of the electric fluid sensor. In
some embodiments, the valve is a motorized ball valve. In some
embodiments, the valve is a solenoid valve. In some embodiments,
the DEF flow control device includes a threaded swivel connection
configured to couple the DEF flow control device to the DEF tank.
In some embodiments, the DEF flow control device includes a mandrel
coupled to the electric fluid sensor, such that the mandrel having
a DEF fill port in fluid communication with the DEF tank and the
valve outlet is in fluid communication with the DEF fill port.
In another embodiment, a diesel exhaust fluid (DEF) flow control
device is provided. The DEF flow control device includes an
enclosure containing control circuity and a valve having an inlet
and an outlet and moveable between an open position and a closed
position, the open position configured to enable DEF flow through
the valve and the closed position configured to block DEF flow
through the valve, the valve outlet in fluid communication with the
DEF tank. The DEF flow control device also includes a valve
actuator operable to move the valve between the open position and
the closed position and an electric fluid sensor disposed in a
sensor housing and having a shaft extending into the DEF tank, the
shaft having a slot such that the electric fluid sensor senses DEF
when the slot is submerged. The DEF flow control device also
includes a mandrel coupled to the electric fluid sensor and having
a DEF fill port for providing fluid to a DEF tank, such that the
valve outlet is in fluid communication with the DEF fill port. The
DEF flow control device further includes a battery configured to
power the control circuity, the valve actuator, and the electric
fluid sensor. The control circuity includes logic configured to
move the valve between the open position and the closed position in
response to a signal provided by the electric fluid sensor.
In some embodiments, the valve is a motorized ball valve. In some
embodiments, the valve is a solenoid valve. In some embodiments,
the DEF flow control device includes a threaded swivel connection
configured to couple the DEF flow control device to the DEF tank.
In some embodiments, the DEF flow control device includes a
pressure gauge configured to measure pressure at the inlet.
In some embodiments, a method of controlling diesel exhaust fluid
(DEF) flow to a DEF tank for a diesel engine. The method includes
using a DEF flow control device coupled to the DEF tank, the DEF
flow control device configured to stop the flow of DEF from a
supply tank when the DEF flow control device detects fluid via an
electric fluid sensor extending into the DEF tank. The DEF flow
control device includes an enclosure containing control circuity
and a valve having an inlet and an outlet and moveable between an
open position and a closed position, the open position configured
to enable DEF flow through the valve and the closed position
configured to block DEF flow through the valve, the valve outlet in
fluid communication with the DEF tank. The DEF flow control device
also includes a valve actuator operable to move the valve between
the open position and the closed position and the electric fluid
sensor disposed in a sensor housing and having a shaft extending
into the DEF tank, the shaft having a slot such that the electric
fluid sensor senses DEF when the slot is submerged. The DEF flow
control device also includes a battery configured to power the
control circuity, the valve actuator, and the electric fluid
sensor. The control circuity includes logic configured to move the
valve between the open position and the closed position in response
to a signal provided by the electric fluid sensor.
In some embodiments, the DEF flow control device is in fluid
communication with a supply line of a gravity fed system. In some
embodiments, the diesel engine provides power to a fluid pump. In
some embodiments, the valve is a motorized ball valve.
In another embodiment, a diesel exhaust fluid (DEF) refilling
system is provided. The system includes a supply tank having DEF
and positioned at a higher elevation than an inlet of a DEF tank
configured to supply DEF to a diesel engine, a supply line
connecting the supply tank to the DEF tank, and a DEF flow control
device in fluid communication with the supply line, the DEF flow
control device configured to enable DEF to flow via gravity from
the supply tank into the DEF tank when the DEF in the DEF tank is
below a predetermined level and configured to block DEF flow into
the DEF tank when the DEF in the DEF tank is at the predetermined
level.
In some embodiments, the system includes a feeder line, the feeder
line further connecting the main supply line to the DEF tank. In
some embodiments, the supply tank is positioned on a deck of a
frame raised to the higher elevation. In some embodiments, the
diesel engine provides power to a fluid pump.
In another embodiment, a DEF flow control device is provided. The
DEF flow control device includes an enclosure containing control
circuity and a valve having an inlet and an outlet and moveable
between an open position and a closed position, the open position
configured to permit DEF flow through the valve and the closed
position configured to block DEF flow through the valve outlet, the
valve outlet in fluid communication with a DEF fill port. The DEF
flow control device further includes a valve actuator operable to
move the valve between the open position and the closed position,
means for sensing DEF in a DEF tank and generating a signal in
response thereto, a mandrel comprising a DEF fill port for
providing fluid to the DEF tank, such that the valve outlet is in
fluid communication with the DEF fill port. The control circuity
includes logic configured to move the valve between the open
position and the closed position in response to the signal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a side perspective view of a bulk storage tank fluid
reservoir of an example gravity-fed system in a raised orientation
in accordance with an embodiment of the disclosure;
FIG. 2 depicts a schematic view of a representative layout of a DEF
system used with various diesel engines in accordance with an
embodiment of the disclosure;
FIGS. 3 and 4 are 3-D perspective views respectively of a electric
DEF flow control device in accordance with an embodiment of the
disclosure; and
FIGS. 5 and 6 are 3-D bottom perspective views of the electric DEF
flow control device of FIGS. 3 and 4 in accordance with an
embodiment of the disclosure.
DETAILED DESCRIPTION
The present disclosure will be described more fully with reference
to the accompanying drawings, which illustrate embodiments of the
disclosure. This disclosure may, however, be embodied in many
different forms and should not be construed as limited to the
illustrated embodiments. Rather, these embodiments are provided so
that this disclosure will be thorough and complete, and will fully
convey the scope of the disclosure to those skilled in the art.
Embodiments of the disclosure include an automated DEF system and
process that provides DEF refilling after an initial setup and
without manual intervention. The automated DEF system and process
reduces or eliminates the time and labor associated with manual DEF
refilling and creates a cleaner environment for tanks, the DEF, and
the associated equipment. The automated DEF system includes an
electric DEF flow control device that controls the flow of DEF to
DEF tanks located at a diesel engine (for example, a pump).
In some embodiments, the DEF may be supplied using a gravity-fed
system or a pump-based system. For example, in some embodiments, a
pump based system may include a pump that maintains a specific
range of pressures. In some embodiments, the gravity-fed system may
be similar to that described in U.S. Pat. No. 10,604,403, a copy of
which is incorporated by reference in its entirety.
For example, FIG. 1 depicts a side perspective view of a bulk
storage tank fluid reservoir 102 of an example gravity-fed system
100 in a raised orientation of an external frame 104 in accordance
with an embodiment of the disclosure. As shown in FIG. 1, a first
DEF supply tank 106 may be positioned on a front deck of the
external frame and a second DEF supply tank 108 may be positioned
on a rear deck of the external frame. Each DEF supply tank may
include a sight tube 110 for determining the DEF level in the tank.
In some embodiments, the supply tanks may be connected by an
equalization line 112. In some embodiments, the DEF supply tanks
may also include electric level monitors.
FIG. 2 depicts a schematic view of a representative layout of a DEF
system 200 used with diesel engines (for example, pumps 202 and
other equipment) in accordance with an embodiment of the
disclosure. FIG. 2 illustrates a gravity supply unit 204
representative of an elevated DEF supply tank that enables gravity
supply of DEF, such as shown in FIG. 1. The connections shown in
FIG. 2 are described with reference to a gravity-fed system having
the gravity supply unit 204 shown in FIG. 2. However, it should be
appreciated that the connections shown in FIG. 2 may be generally
applicable to embodiments using a pump-based system. For example,
FIG. 2 also shows a trailer 206 having a pump-based DEF supply and
a DEF storage.
As shown in FIG. 2, the feeder lines 208 may be connected to main
supply lines 210 that route from the gravity supply unit 204 to the
first pump 202. In some embodiments, the main supply lines 210 are
1 inch diameter lines. Each bank of pumps 202 may have a main
supply line. In some embodiments, the main supply lines 210 from
the gravity supply unit 204 to the first pump 202 may not include
any connections except for a "no-drip" stainless steel quick
connect on the ends of the lines, male by female. In other
embodiments, other types of connections may be used. When a main
supply line reaches equipment that uses DEF, a manifold 212 may be
connected to the line. That manifold may have the same size
connections on each end as the main supply lines 210. In some
embodiments, the manifold is stainless steel and may have multiple
ports (for example, about 0.5 inch ports) to connect equipment to
the main supply line with smaller lines (for example, 0.5 inch in
diameter). In some embodiments, the smaller lines may have "no
drip" stainless quick connects, male by female. In other
embodiments, other types of connections may be used. FIG. 2 also
depicts other equipment such as, for example, blenders 214,
hydration units 216, chemical addition units 218, sand belts 220,
and dual belt 222, that may, in some embodiments, include or be
powered by diesel engines and use the DEF system 200 described in
the disclosure.
After the main supply lines are routed to the first pump on each
bank, a pump main supply line 224 may be used to further supply
each piece of equipment (for example, pumps 202). In some
embodiments, each pump main supply line 224 may include tees
located at constant intervals to connect feeder lines 208 to each
piece of equipment. In some embodiments, a pump main supply line
224 may include tees about every 11 feet, and the tees may include
0.5 inch connections for coupling to 0.5 inch diameter feeder
lines. In some embodiments, four pieces of equipment may be able to
connect to one pump main supply line, with the lines running behind
the pumps. Advantageously, this configuration enables pumps to be
easily replaced, swapped out, or pulled forward for maintenance
without interference with the lines.
The automated DEF system includes a DEF flow control device.
Components of the electric DEF flow control device 300 are shown in
FIGS. 3-6 and described below. FIGS. 3 and 4 depict front and rear
perspective views of the electric DEF flow control device 300 in
accordance with an embodiment of the disclosure. FIGS. 5 and 6
depict 3-D perspective views of the bottom of the electric DEF flow
control device 300 in accordance with an embodiment of the
disclosure.
The electric DEF flow control device 300 includes an electronics
enclosure 302 that encloses control circuity and a battery, an
electric fluid sensor 304, a motorized ball valve 306 and ball
valve actuator 308, a ball valve position indicator 310, connector
312 (for example, a quick connect) on one side of the motorized
ball valve 306, and on another side of the motorized ball valve a
series of connections and hose 354 (for example, a stainless steel
hose) that connects the discharge side of the motorized ball valve
306 to the top of the mandrel 324, a beacon light 316, a status
light 318, a button 320, a component plate 322, a mandrel 324, and
a pressure gauge 326.
The electronics enclosure 302 may include one or more batteries. In
some embodiments, the electronics enclosure 302 includes three D
cell batteries. In other embodiments, other batteries may be
included. In other embodiments, other batteries may be included.
Additionally or alternatively, the electric DEF flow control device
300 may be powered by other power sources, such as on-board
batteries or solar power.
The control circuity in the electronics enclosure 302 may include
hardware and/or software logic to control the operation of the
electric DEF flow control device 300, such as the operation of the
electric fluid sensor 304 and the motorized ball valve 306. For
example, in some embodiments the control circuity may include a
programmable microcontroller or a field programmable gate array
(FPGA). The control circuity may have different configurations
depending on the desired operation of the electric DEF flow control
device 300. In some embodiments, the control circuity includes or
is implemented on a circuit board. The control circuity may also
include a radio receiver, transmitter, or transceiver for radio
communication, such as with personnel at the wellsite or a
communication hub. In some embodiments, the control circuitry may
include a network interface for communication over various
networks. In such embodiments, the electric DEF flow control device
300 may communicate a status to a remote device. The status may be
communicated periodically, in response to a change in operation of
the device 300, or a combination thereof. In some embodiments, the
control circuity enables hands free and automatic operation of the
electric DEF flow control device 300. In some embodiments, the
control circuity initiates a battery function test periodically or
on demand. In such embodiments, the control circuity may initiate a
notification if a battery fails. In some embodiments, the
notification includes flashing the beacon light 316 in a pattern
(for example, 3 times every 15 seconds).
The electronics enclosure 302 that encloses the control circuity
may be weatherproof and enclose other components of the electric
DEF flow control device 300. In some embodiments, the electronics
enclosure 302 may enclose the battery and may include connections
to other components of the electric DEF flow control device 300,
such as connections to the electric fluid sensor 304, the motorized
ball valve 306, the beacon light 316, the status light 318, and the
button 320. For example, in some embodiments a sensor wire 328 may
be coupled to a side of the electronics enclosure 302 and enable
electrical communication with the electric fluid sensor 304. In
some embodiments, a valve control wire 330 may be coupled to a side
of the electronics enclosure 302 (for example, via valve control
wire connector 332) and enable electrical communication with the
motorized ball valve 306. In some embodiments, the electronics
enclosure 302 includes a removable lid 334 that provides access to
the interior of the electronics enclosure 302 but seals the
enclosure 302 from liquids and particulates such as dust when
attached. The removable lid 334 may be secured to another portion
of the electronics enclosure 302 via fasteners (for example,
screws).
The electric DEF flow control device 300 includes a dampening
bracket 336 that secures the electronics enclosure 302 (that is, to
secure the internal components such as the control circuity and
battery), ball valve 306, ball valve actuator 308 to the component
plate 322 of the electric DEF flow control device 300. The bracket
336 may reduce or eliminate vibration of components during handling
and operation of the electric DEF flow control device 300. The
bracket 336 may be secured to the electronics enclosure 302, ball
valve 306, ball valve actuator 308, and other components via
fasteners such as bolts, screws, or other suitable fasteners.
In some embodiments, the electric fluid sensor 304 may be formed
from stainless steel and may have dimensions that reduces the
footprint of the electric DEF flow control device 300. In some
embodiments, the electric fluid sensor 304 is housed in a sensor
housing 336 and includes a shaft 338 inside the sensor housing 336.
The shaft 338 includes an opening (for example, a slot or a notch).
The electric fluid sensor 304 transmits an ultrasonic signal across
the opening that is only detectable when the opening is immersed in
fluid, thus indicating that fluid is present. As shown in the
figures, the sensor housing 336 includes holes 340 to allow fluid
into the sensor housing 336 to contact the shaft 338.
The interior of the sensor housing 336 may include a threaded
connection which, in some embodiments, may also include a sealing
component (such as an o-ring), such that the sensor shaft 338
protrudes from the bottom of the housing 336. In some embodiments,
the sensor housing 336 may have a length longer than the sensor
shaft 338 to protect the end of the sensor shaft 338. The upper
portion of the sensor housing 336 includes a recess that houses
some of the upper portion of the sensor 304. The upper portion of
the sensor housing 336 may couple to the lower portion via a
threaded connection and a sealing component (such as an o-ring). In
some embodiments, the outside of the upper portion of the sensor
housing 336 is tapered to enable easier removal from the connection
port on a DEF tank. The top side of the upper portion of the sensor
housing may include a threaded portion (for example, a 0.5 inch NPT
thread) to couple to the flexible hose 352 which couples the sensor
housing to the mandrel 324.
In other embodiments, other sensing devices or technologies may be
used to detect the presence of fluid instead of the electric fluid
sensor 304. For example, in other embodiments the electric DEF flow
control device 300 may include a vibration sensor, a pressure
transducer, radar, a rod sensor, a float switch, or other types of
sensing devices or technologies.
The motorized ball valve 306 may be configured to move between a
closed position that blocks DEF flow and an open position that
enables DEF flow. The movement between the open position and closed
position may be controlled by the control circuity in response to a
signal from the electric fluid sensor 304. The motorized ball valve
may include an electric motor (included in or housed in the ball
valve actuator 308) and a stainless steel ball valve. In other
embodiments, the ball valve may be formed from brass or carbon
steel. The electric motor may open and close the ball valve 306 to
enable movement between the open position and closed position. In
some embodiments, the motorized ball valve 306 includes the valve
position indicator 310, such as on top of the ball valve actuator
308, which indicates whether the motorized ball valve 306 is open
or closed. The valve position indicator 310 may enable a technician
to visually verify the position of the motorized ball valve 306. In
other embodiments, other types of valves may be used instead of the
motorized ball valve 306. For example, in other embodiments the
electric DEF flow control device 300 may include a solenoid valve,
a pneumatic valve, or other type of valve.
The motorized ball valve 306 may be coupled to the connector 312
via a tee connector 342 that enables connection of the pressure
gauge 326. The pressure gauge 326 may enable visual monitoring of
the pressure of the DEF received by the motorized ball valve
306.
In some embodiments, the beacon light 316 is a light emitting diode
(LED), such as a red LED. In other embodiments, other types of
lights may be used. In some embodiments, the beacon light 316 is
positioned to be visible from all sides of the electric DEF flow
control device 300, such as on top of the electronics enclosure
302. In some embodiments, the beacon light 316 provides an
indicator for notifications (for example, alarms) of the electric
DEF flow control device 300. For example, in some embodiments the
beacon light 316 indicates when the device has not sensed fluid for
a configurable period of time, thus indicating a potential issue
with the automated DEF system or tanks. The beacon light 316 may
also indicate when the device is put into standby mode, when the
device is put into operational mode, when the device has a low
battery, and other possible indications.
In some embodiments, the status light 318 is a light emitting diode
(LED), such as a green LED. In other embodiments, other types of
lights may be used. In some embodiments, the status light 318 is
positioned to be visible from all sides of the electric DEF flow
control device 300, such as on top of the electronics enclosure
302. In some embodiments, the status light 318 provides an
indicator of activity of the electric DEF flow control device 300.
For example, in some embodiments the status light 318 may flash
each time the control circuitry receives or obtains a signal from
the electric fluid sensor 304. In some embodiments, the status
light 318 may flash when the button of the electric DEF flow
control device 300 is pushed, or as a status light 318 that flashes
to show normal operating condition
The button 320 may be weatherproof and may initiate one or more
functions of the electric DEF flow control device 300. In some
embodiments, the button 320 may perform different functions based
on the duration of a button 320 press. For example, in some
embodiments pushing the button 320 for a first duration (such as
less than 1 second) may initiate obtaining a signal from the
electric fluid sensor 304 (that is, immediate activation of the
electric fluid sensor), such as for testing the device and
activating the device to verify normal operation. In another
example, pushing the button 320 for a second duration (such as
greater than 10 seconds) may cause the device to enter into an
operational or standby mode. It should be appreciated that the
button 320 may be programmed to perform different or additional
functions.
The component plate 322 couples to the mandrel 324 via fasteners
(for example, bolts 344), and corresponding holes and to the
bracket via the previously mentioned fasteners The component plate
322 may provide access to the mandrel 324 for routing of the sensor
wire to the electric fluid sensor and for connection of the
motorized ball valve 306 to the mandrel DEF port.
As shown in the figures, electric DEF flow control device 300
includes additional components that enable insertion of the
electric fluid sensor 304 into a DEF tank and flow of DEF into a
DEF tank (as controlled by the motorized ball valve 306). The
electric DEF flow control device 300 includes a 90-degree connector
346, a DEF fill port 348 in the mandrel 324, a threaded swivel
connector 350 (for example, a 1.5 inch National Pipe Tapered (NPT)
threaded swivel connector), and a flexible hose 352 that couples
the mandrel 324 to the electric fluid sensor 304.
The component plate 322 may secure the threaded swivel connection
350 on the mandrel 324 on the top side to maintain the connection
between the greater outer diameter below and the plate 322 above.
Additionally, the component plate 322 may secure the bracket 336
that supports the enclosure 302.
The threaded swivel connection 350 may include a hexagonal upper
end and a threaded lower end. The threaded swivel connection 350
may include an internal o-ring receptacle (for example, a groove)
and an o-ring in the receptacle to seal the connector 350 to the
mandrel 324 and prevent water and debris from entering a DEF
tank.
The upper portion of the mandrel 324 has an outer diameter that
fits inside the threaded swivel connection 350 and may seal against
the internal o-ring of the threaded swivel connection 350. The
lower portion of the mandrel 324 has a larger outer diameter that
may prevent the threaded swivel connection 350 from sliding off of
the bottom, thus retaining the threaded swivel connection 350. The
mandrel 324 may include two ports at the top side with two bolt
holes. One port may be used as a DEF fill port and allows DEF to
pass through the port and into a DEF tank. The 90-degree connector
346 may be coupled to the top side of the mandrel 324 and connected
to the port. The other port may be used as a path to route the
sensor wire 328 for the electric fluid sensor 304. In some
embodiments, the ports may each be a 0.25 inch NPT port. The bottom
side of the mandrel 324 may include holes or ports that connect to
the two ports on the top side of the mandrel. For example, in some
embodiments the bottom side may include a 0.25 inch straight hole
and a 0.5 inch NPT port. The 0.25 inch straight hole may be used as
the DEF fill port 348 for the DEF flow and may connect to the upper
0.25 inch NPT port. The 0.5 inch NPT port may connect to the other
upper 0.25 inch NPT port for the sensor cable path and provides a
connection point for the flexible hose 352 from the sensor
housing.
As also shown in the figures, the electric DEF flow control device
300 includes a hose 354 connecting the 90-degree connector 346 to
the connector 314 of the motorized ball valve 306. The other
connector 312 of the motorized ball valve 306 may be connected to a
feeder line for DEF (for example, from a gravity supply tank), such
that the motorized ball valve 306 controls the flow of DEF from the
feeder line to the DEF fill port and into a DEF tank. In some
embodiments, the hose 354 may be a stainless steel hose. It should
be appreciated that FIGS. 5 and 6 illustrate a different embodiment
in which a hose is connected to the mandrel 324 and connector 314
via different connectors that the 90-degree connector 346. For
example, the hose shown in FIGS. 5 and 6 may be a rubber hose.
Additionally, FIGS. 5 and 6 omit illustration of the sensor wire
for clarity.
In some embodiments, the flexible hose 352 may be a 0.5 inch
diameter stainless steel hose. The flexible hose 352 may provide a
path for routing the sensor wire to the electric fluid sensor 304.
Additionally, the flexible hose 352 may provide a flexible
connection between the mandrel 324 and the sensor housing 336 to
enable the electric DEF flow control device 300 to be installed on
obstructed DEF tanks (that is, DEF tanks with obstacles above the
connection port).
Advantageously, the electric DEF flow control device 300 may run
solely on battery power without using solar power or other external
power sources. In some embodiments, the battery may be of
sufficient capacity to enable the electric DEF flow control device
300 to operate for a time period of at least 6 months. Moreover,
the electric DEF flow control device 300 is compact and does not
require any external connections or signals to operate. For
example, the electric DEF flow control device 300 does not require
a cable or a central control unit and eliminates the risk of a bad
cable or network connection. Thus, the electric DEF flow control
device 300 may function alone without any other devices and does
not require proximity to any other devices (that is, it may operate
at unlimited distances).
In some embodiments, the electric DEF flow control device 300 may
be used with a gravity-fed system, such as that described in U.S.
Pat. No. 10,604,403 The electric DEF flow control device 300 may
enable automated DEF flow control, such that the DEF is provided to
equipment without manual intervention from a technician. In such
embodiments, DEF may flow from the gravity unit, through the main
supply lines into the feeder lines, and through the electric DEF
flow control device 300 into a DEF tank. When the electric fluid
sensor 304 senses fluid (that is, when the fluid in the tank has
reached a desired level), the electric DEF flow control device 300
may move the motorized ball valve to the closed position and stop
the flow of fluid. The electric DEF flow control device 300
periodically obtains a signal from the electric fluid sensor 304 at
programmable intervals (that is, intervals programmed into and
stored by the control circuity). If the electric fluid sensor 304
does not detect any fluid for a programmable time period (that is,
a time period programmed into and stored by the control circuity),
the electric DEF flow control device 300 may move the motorized
ball valve 306 to the open position and enable the flow of fluid to
refill the DEF tank. Thus, in order for the motorized ball valve
306 to move to the open position after closing, the electric fluid
sensor 304 must by "dry" (that is, not sensing fluid) for the time
period. When the electric fluid sensor 304 subsequently senses
fluid (that is, when the fluid in the tank has reached a desired
level), the electric DEF flow control device 300 may move the
motorized ball valve to the closed position and stop the flow of
fluid.
In other embodiments, the electric DEF flow control device 300 may
be used as for automated DEF control on other types of systems,
such as pump-based system or other types of DEF supply.
Installation of the electric DEF flow control device 300 will be
described with reference to a gravity-fed system, such as that
described in U.S. Pat. No. 10,604,403. However, it should be
appreciated that the installation procedure described herein may be
applicable and similar to other types of fluid systems.
Initially, the electric DEF flow control device 300 may be
delivered in a package (for example, a box) to a wellsite or other
location where the electric DEF flow control device 300 is to be
used, and removed from the package when ready for installation.
In some embodiments, the electric DEF flow control device 300 may
remain permanently on (such that all components are operational and
cannot be unpowered from the power source). In other embodiments,
the electric DEF flow control device 300 may include an on/off
control (for example, an on/off switch or a specific configuration
of the button 320). Before use, the electric DEF flow control
device 300 may be cleaned. After cleaning, the button 320 may be
depressed and released to activate of the electric fluid sensor
304. The electric fluid sensor 304 will not sense any fluid, and
the motorized ball valve 306 will move to the open position. The
sensor 304 shaft of the electric DEF flow control device 300 may be
submerged in DEF, and the button 320 may be depressed and released
again to activate the electric fluid sensor 304. The electric fluid
sensor 304 will sense fluid, and the motorized ball valve 306 will
move to the closed position. The electric DEF flow control device
300 may remain in the closed position for installation.
Next, the electric DEF flow control device 300 may be installed on
a DEF tank, such as by screwing the threaded swivel connection 350
to a connection port on the DEF tank. A feeder line from the main
supply line of the gravity-fed system may be coupled to the inlet
side of the motorized ball valve 306 of the electric DEF flow
control device 300. The button 320 may be depressed and released to
activate the electric fluid sensor 304. If the electric sensor 304
does not detect any fluid, the motorized ball valve 306 may move to
the open position and the DEF tank will be filled with DEF. If
sensor 304 senses fluid, the motorized ball valve 306 will move to
the closed position.
The electric DEF flow control device 300 may be manually and
periodically checked (for example, every 30 minutes) by observing
the status, including observing the status light 318.
In some embodiments, the electric DEF flow control device 300 may
be checked remotely. Additionally, operation of the electric DEF
flow control device 300 may be checked by observing an indication
of fluid sensor 304 operation (for example, flashing of the status
light 318). For example, in some embodiments a particular flashing
sequence of the beacon light 316 may indicate that the electric
fluid sensor 304 has not sensed fluid in about 6 hours, thus
indicating a potential supply issue or system issue. In another
example, a particular flashing sequence of the beacon light 316
(for example, 3 flashes every 15 seconds) may indicate a low
battery that needs replacement. The status light 318 may also be
observed to indicate proper functioning of the electric DEF flow
control device 300.
If the electric DEF flow control device 300 indicates an alarm (for
example, by flashing the status light 318), the automated DEF
system may be diagnosed and the electric DEF flow control device
300 may be reset when the system has returned to normal
operation.
Ranges may be expressed in the disclosure as from about one
particular value, to about another particular value, or both. When
such a range is expressed, it is to be understood that another
embodiment is from the one particular value, to the other
particular value, or both, along with all combinations within said
range.
Further modifications and alternative embodiments of various
aspects of the disclosure will be apparent to those skilled in the
art in view of this description. Accordingly, this description is
to be construed as illustrative only and is for the purpose of
teaching those skilled in the art the general manner of carrying
out the embodiments described in the disclosure. It is to be
understood that the forms shown and described in the disclosure are
to be taken as examples of embodiments. Elements and materials may
be substituted for those illustrated and described in the
disclosure, parts and processes may be reversed or omitted, and
certain features may be utilized independently, all as would be
apparent to one skilled in the art after having the benefit of this
description. Changes may be made in the elements described in the
disclosure without departing from the spirit and scope of the
disclosure as described in the following claims. Headings used in
the disclosure are for organizational purposes only and are not
meant to be used to limit the scope of the description.
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